Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
  • B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
  • B01J20/16—Alumino-silicates
  • B01J20/18—Synthetic zeolitic molecular sieves
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S95/00—Gas separation: processes
  • Y10S95/90—Solid sorbent
  • Y10S95/902—Molecular sieve

Definitions

• the present invention relates in general to the elimination of odors, and more particularly, to the process for removing odor-causing organic compounds from a liquid or gaseous medium by contact of the medium with a crystalline molecular sieve having certain critical physical and chemical properties hereinafter elucidated.
• the invention also relates to molecular sieve compositions suitable for use in the process.
• odors are the interaction of high frequency radiations emitted by odorous substances with pigment granules in the olfactory receptors.
• the radiations are derived from the characteristic molecular vibration of each specific odorous substance, and distinctions between the various odors are made on the basis of the differences in wave lengths of the emitted radiations.
• it is the reactivity of functional portions of molecular species with olfactory receptors which is perceived by the brain as odor.
• the energy of the precise stimulus of odor receptors is derived electrochemically from an odorous material, more particularly from a modification of the bonding angles of a molecular species upon solution in the olfactory mucosa and a consequent alteration or unbalance of the electrostatic fields detected by the olfactory receptors.
• This theory could explain why multiple substances of quite different chemical structure may have the same or similar odors, and also why a mixture of two or more odorous substances may be perceived as having no odor.
• the preferred species have been those with a low framework Si/Al ratio and a high degree of adsorption capacity for water or other highly polar molecules such as ammonia or hydrogen sulfide.
• the disclosure of the aforesaid U.S. Pat. No. 4,437,429 is somewhat remarkable for its specific disclosure of many of the class of so-called high silica zeolites which are synthesized using organic templating agents such as the tetraalkylammonium ions. These include ZSM-5, ZSM-11, ZSM-12 and ZSM-23.
• the preferred zeolite species is the natural mineral clinoptilolite, however, which has a nominal framework SiO 2 /Al 2 O 3 molar ratio of about ten. It has also been proposed, U.S. Pat. No. 4,648,977, to use high-silica molecular sieves, including the silica polymorph silicalite, to adsorb toxic organic materials, including mercaptans, from aqueous media for water purification purposes.
• odors of certain odorous organic compounds can be essentially eliminated by contact at a temperature within the range of from -25° C. to 100° C., preferably 0° C. to 40° C., with a crystalline siliceous molecular sieve in which at least about 90, and preferably at least about 95, percent of the framework tetrahedral oxide units are SiO 2 tetrahedra and which have a sorptive capacity for water at 25° C. and 4.6 torr of less than 10 weight percent.
• aluminosilicate molecular sieves those useful in the practice of the invention have a framework SiO 2 /Al 2 O 3 molar ratio of from about 35 to infinity, and preferably from 200 to 500. All of the siliceous molecular sieves suitably employed have a pore diameter of at least 5.5 Angstroms, preferably at least 6.2 Angstroms. Preferably the adsorption capacity for water vapor at 25° C. and a water vapor pressure (p/p o ) of 4.6 torr is less than 6 weight percent.
• the efficacy of the molecular sieves employed in the practice of the present invention is not dependent upon the presence of the water of hydration present in the internal cavities of the microporous structure as a result of their hydrothermal formation.
• at least a major proportion, usually substantially all, of this original water of hydration is removed in the process of removing any pore-blocking templating agent which may be present in the adsorbent. Calcination effectively removes the organic moieties.
• water washing or washing with a caustic or dilute mineral acid solution is advantageously utilized to remove extraneous synthesis reagents from the pore system. Lowering of the alkali metal content, particularly the non-zeolitic, i.e., occluded alkali metal compounds can also be beneficial. These procedures also serve to remove the original water of hydration.
• the odorous organic compounds suitably treated in the present process can be any organic molecular species having a vapor pressure at 23° C. of greater than 1 mm Hg. It has been observed that many of the compounds having the more objectionable odors, when added to liquid water lowers the surface tension thereof. These compounds are a preferred class of odor-causing materials for treatment in accordance with the present invention.
• the overall class of substances which can be suitably treated have pleasant as well as unpleasant odors as perceived by human beings. Accordingly, since the greatest benefit of odor control is likely to attend the elimination of those which are generally conceived of as unpleasant, it is preferred that the organic compounds treated in the present process are classifiable in one of the following subgeneric classes:
• saturated or unsaturated aliphatic acids and aldehydes containing a single --COOH or --CHO group and containing less than 12 carbon atoms such as acetic, propionic, butyric, valeric, isovaleric (alpha-methylbutyric), caproic and caprylic acids.
• organic sulfur-containing compounds in which the valence of the sulfur atom is less than 6, especially those in which the valence of sulfur is 2, such as the sulfhydryl compounds, i.e. mercaptans and thiophenols of the general formula R--S--H wherein "R" represents an alkyl or alkenyl group containing from 1 to 8 carbon atoms or a phenyl or substituted phenyl group containing from 6 to 9 carbon atoms; the sulfides of the general formula R--(S) n --R wherein n has a value of from 1 to 4 and "R" represents the same groups as in the case of the aforesaid sulfhydryl compounds; the thioaldehydes and thioketones of the general formula ##STR1## wherein R' is hydrogen or R, and R is an alkyl or alkenyl group containing from 1 to 8 carbon atoms or a phenyl or substituted
• organic nitrogen-containing compounds in which the valence of the nitrogen atom is 3, such as the aliphatic amines of the general formula R 2 NR' wherein R is hydrogen or R' and R' is an alkyl or alkenyl group having from 1 to 6 carbon atoms; and the heterocyclic nitrogen compounds containing an imino group in which the nitrogen atom is a part of the heterocyclic ring, particularly the pyrroles, and especially the pyrroles in which the alpha position is unsubstituted, and the condensed pyrroles which are the indoles, i.e. indole per se and the substituted derivatives thereof.
• organic nitrogen-containing compounds in which the valence of the nitrogen atom is 3, such as the aliphatic amines of the general formula R 2 NR' wherein R is hydrogen or R' and R' is an alkyl or alkenyl group having from 1 to 6 carbon atoms; and the heterocyclic nitrogen compounds containing an imino group in
• Specific compounds within the three subclasses designated above are acetic acid, propionic acid, butyric acid, gamma-hydroxybutyric acid, valeric acid, isovaleric acid (alphamethylbutyric acid), caproic acid, caprylic acid, isobutyraldehyde, methyl mercaptan, ethyl mercaptan, propyl mercaptan, allyl mercaptan, iso-amyl mercaptan, n-butyl mercaptan, crotyl mercaptan, thiophenol, o-methyl thiophenol, allyl disulfide, allyl sulfide, diallylsulfide, amyl sulfide, benzyl sulfide, thiocresol, thioisobuteraldehyde, thioiisovaleraldehyde, ⁇ -hydroxypropylmethyl sulfide,
• the siliceous molecular sieves suitably employed in the practice of the invention include the microporous crystalline aluminosilicates, i.e. the zeolitic molecular sieves as well as the so-called silica polymorphs. With respect to the latter compositions, their crystal lattices are ideally formed entirely of SiO 2 tetrahedral units, but the as-synthesized forms commonly contain at least trace amounts of aluminum derived from aluminum impurities in the synthesis reagents.
• the aluminosilicate molecular sieves comprise the large class of well-known crystalline zeolites.
• the adsorptive capacity for water of the siliceous molecular sieve is less than 10 weight percent under the conditions set forth above. It is another critical aspect that the number of AlO 2 tetrahedral units of the crystal lattice, if present at all, be very small compared with the number of SiO 2 tetrahedral units. It has been observed that there appears to be some correlation between the framework SiO 2 /Al 2 O 3 ratio and the adsorptive capacity for water, i.e., the so-called hydrophobicity, of siliceous molecular sieves.
• molecular sieve adsorbents are capable of such extreme selectivity as to be able to effectively sequester molecules of organic species to such a degree that residual concentrations over the adsorbent are below the detection threshold.
• organophilic selectivity is involved in the present process. Without wanting to be bound by any particular theory or theories, it is believed likely that one or more of the following phenomena are involved.
• a catalytic process is involved whereby the odor molecules are reacted inter se or with other available molecular species such as oxygen to form compounds or polymers which no longer stimulate the olfactory receptors.
• high molecular weight organic molecules are significantly less odorous than low molecular weight molecules of similar atomic content and structure; n-decyl and lauryl mercaptans have no more odor than their corresponding alcohols.
• polymerization or condensation reactions could be beneficial in the present process.
• the class of medium to large pore siliceous molecular sieves defined hereinabove from which the original, as-synthesized water of hydration has been substantially removed, and which have a capacity for adsorbed water of not greater than 10, and preferably not greater than 6, weight percent when measured at 25° C. and a water vapor pressure (p/p o ) of 4.6 torr, function in an extraordinary manner with respect to odor elimination.
• Many of the synthetic zeolites prepared using organic templating agents are readily prepared in a highly siliceous form--some even from reaction mixtures which have no intentionally added aluminum. These zeolites are markedly organophilic and include ZSM-5 (U.S. Pat. No.
• silica molecular sieves known as silicalite and F-silicalite are particularly suitable for use in the present invention and are thus preferred. These materials are disclosed in U.S. Pat. No. 4,061,724 and 4,073,865, respectively.
• siliceous sieves are synthesized to have SiO 2 /Al 2 O 3 ratios greater than 35, they are frequently suitable for use in the present process without any additional treatment to increase their degree of hydrophobicity.
• Molecular sieves which cannot be directly synthesized to have both sufficiently high Si/Al and/or degree of hydrophobicity ratios can be subjected to dealumination techniques, fluorine treatments and the like, which result in organophilic zeolite products. High-temperature steaming procedures for treating zeolite Y which result in hydrophobic product forms are reported by P. K. Maher et al., "Molecular Sieve Zeolites," Advan. Chem. Ser.
• the pore system be open so that the internal cavities of the crystals be accessible to the odor molecules.
• organic templating ions such as tetraalkylammonium ions
• the original water of hydration is also removed.
• the molecular sieve can be employed in either a hydrated or dehydrated state, but in general the dehydrated state is preferred.
• the original water of dehydration is also removed, and can similarly be replaced, if desired, for the practice of the invention.
• the method for contacting the odor source with the siliceous molecular sieve adsorbent is not narrowly critical, but is accomplished in a manner that molecular, as distinguished from ionic organic species, are contacted even though liquid water or water vapor is present.
• the process is believed to be basically an adsorptive process rather than an ion-exchange process.
• the siliceous molecular sieve can be present in a formulation with diluents, carriers, dispersing media and the like, even aqueous media, and applied to the odor source in that form.
• the formulation may be in the form of a powder, an agglomerate, an aerosol or in shaped forms, i.e.
• monoliths which can be directly applied to a concentrated source of the odor or be positioned within a zone through which a gas stream containing the odor molecules are entrained.
• Specific applications include the incorporation of the adsorbents in body powders, foot powders, genital sprays, menstrual pads, cat litter, diapers, hand cream, mouthwash, non-woven tissues and the like for the treatment of odors in bathrooms, kitchens, garbage compactors and cans, refrigerators, closets etc.
• Temperature conditions at contact are not critical, but are preferably within the range of -25° to 40° C., i.e. the ambient atmospheric temperature occurring in any season and in any geographical location. Pressure is also not a critical factor, but is preferably at least about one atmosphere.
• the present process is illustrated by the examples appearing hereinafter.
• a number of high silica aluminosilicates and silica polymorphs were exposed to various odorous substances in a reproducible and consistent manner to determine the absolute or relative amounts of odors adsorbed.
• 40 ml. screwcap vials equipped with Teflon-lined silicone rubber septa were used. The vials were measured to have a capacity of 43.5 ⁇ 0.1 ml.
• the activated charcoal adsorbent used was 70/80 mesh chromatographic grade from Analabs, Inc., Hamden Conn., and was labeled ANASORB grade.
• the adsorbent of interest was weighed into the vial and the vial was capped.
• the adsorbate was added to the sealed vial with a Hamilton syringe. Samples were shaken by hand to mix the liquid/solid/vapor phases and the vapors in the headspace of the vials were analyzed by gas chromatography within 5 to 20 minutes after weighing and mixing.
• the pure compounds were placed into 43.5 ml. capacity vials and stored for at least one hour prior to analysis. Generally 2 microliter aliquots from the headspace of the 43.5 ml. vials were analyzed; 2 microliters of room air was injected to maintain consistent atmospheric pressure.
• the syringe needle Prior to and after each sample injection the syringe needle was placed into a 200° C. syringe cleaner under vacuum (estimated pressure ⁇ 5 ⁇ 10 -3 torr). As a heat source a 100 watt light bulb was placed over the syringe at a distance of 1 to 2 inches. This was done to eliminate any cross contamination from vapor molecules adsorbed on the Teflon parts of the syringe. The heating under vacuum was done for approximately 5 minutes prior to use. Analysis of room air after this cleaning procedure showed no contamination in the syringe.
• Gas chromatographic analytical techniques were employed to measure the concentration of odor components in the headspace of the sample vials.
• the column was a 0.32 mm. I.D. ⁇ 30 meters, fused silica adsorbent capillary containing a 1 micron internal coating of Carbowax as the adsorbent.
• a flame ionization detector was utilized to determine retention times. The oven conditions were 50° C. for four minutes and then raised to 150° C. at the rate of 10° C. per minute.
• adsorbent materials were tested for their ability to deodorize the airspace over triethylamine, a common constituent of various animal and human excretions.
• 500 mg. of the adsorbent solid were placed in a 43.5 ml. vial and the triethylamine added in sufficient quantity to give a weight loading of triethylamine of 4.37%.
• triethylamine was placed in a vial with no adsorbent.
• the headspace vapors in the vials were analyzed in the same manner as described hereinabove.
• the adsorbent identified as LZ-20 in Example 3, and in subsequent Examples, is a steam-stabilized form of zeolite Y prepared in a manner essentially the same as employed in the preparation of LZ-10 except the steaming conditions were less rigorous resulting in a product having a water adsorption capacity at 25° C. and a water vapor pressure (p/p o ) of 4.6 torr of about 10 weight percent, a sodium content (as Na 2 O) of 0.2 weight percent (anhydrous basis).
• the adsorbent identified as LZ-105-5 in Example 10 and subsequent examples was a zeolite of the ZSM-5 type prepared in the absence of organic templating material and acid-washed to produce a zeolite having a SiO 2 /Al 2 O 3 molar ratio of about 36.7 and a Na 2 /Al 2 ratio of 1.19.
• the adsorbent composition of Example 6 was an equal parts by weight mixture of LZ-10 and silicalite. The analytical results are set forth below in tabular form.
• Example 21 The same test as Example 21 was conducted on a number of other materials. The results are:
• a zeolite Beta having a framework SiO 2 /Al 2 O 3 molar ratio of 25.4 and a water sorption capacity at 25° C. and 4.6 torr of 14.28 weight percent was contacted with isovaleric acid. It was found by a subjective "sniff" test that an appreciable amount of odor due to the isovaleric acid remained after contact with the adsorbent.
• silica polymorph TEA-silicate (U.S. Pat. No. 4,104,294) having a framework Si/Al 2 molar ratio of 381 and which in general is characteristically not strongly hydrophobic, was found to have a water sorption capacity at 25° C. and 4.6 torr of only 2.3 weight percent water. When tested with isovaleric acid, some odor was detectable. The reason for this apparent anomaly is now known.

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• 1987
  • 1987-06-30 US US07/067,977 patent/US4795482A/en not_active Expired - Lifetime
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• 1988
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